Layout of liquid crystal display panels and size of mother substrate

ABSTRACT

A layout of LCD panels and a size of the mother substrate are disclosed, to improve the efficiency in arrangement of the LCD panels, and to maximize the substrate efficiency, the layout comprising a mother substrate; a dummy region of 15 mm or less in a periphery of the mother substrate; and six LCD panels of the 26-inch model in a matrix of 2×3 on the mother substrate excluding the dummy region with a margin corresponding to 2˜4% of a length of the LCD panel.

This application is a Continuation-in-Part of U.S. patent applicationSer. No. 10/819,350, filed Apr. 7, 2004 now U.S. Pat. No. 7,414,695,which claims the benefit of the Korean Patent Application No.2003-0021759 filed on Apr. 7, 2003, hereby incorporated by reference forall purposes as if fully set forth herein. This application alsoincorporates by reference Korean Patent Application Nos. P2005-116039filed on Nov. 30, 2005 and P2006-32025 filed on Apr. 7, 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a liquid crystal display (LCD) device,and more particularly, to a layout of liquid crystal display (LCD)panels and a size of a mother substrate to maximize the substrateefficiency.

2. Discussion of the Related Art

With the growth of the information society, demands for various displaydevices has increased. Accordingly, many efforts have been made toresearch and develop various flat display devices, for example, a liquidcrystal display (LCD) device, a plasma display panel (PDP), anelectroluminescent display (ELD) and a vacuum fluorescent display (VFD),and some species of the flat display devices are already applied todisplays of various equipments.

Among the various flat display devices, the LCD device has been mostwidely used due to the advantageous characteristics of compact size,thin profile, and low power consumption, whereby the LCD devicesubstitutes for a Cathode Ray Tube (CRT). In addition to the mobile typeLCD devices such as a display for a notebook computer, the LCD deviceshave been developed for computer monitors and televisions to receive anddisplay broadcasting signals. Especially, as the LCD devices are usedfor the televisions, it is trending toward various and large sizes inthe LCD devices.

In general, the LCD device includes an LCD panel for displaying an imageand a driver for supplying a driving signal to the LCD panel. Inaddition, the LCD panel includes first and second substrates bonded toeach other, and a liquid crystal layer formed between the first andsecond substrates.

The first substrate (referred to as a TFT array substrate) includes aplurality of gate lines arranged along a first direction at fixedintervals, a plurality of data lines arranged along a second directionperpendicular to the first direction at fixed intervals, a plurality ofpixel electrodes arranged in a matrix-type configuration within pixelregions defined by the gate and data lines, and a plurality of thin filmtransistors transmit signals from the data lines to the pixel electrodesin accordance with signals supplied to the gate lines.

The second substrate (referred to as a color filter array substrate)includes a black matrix layer that prevents a light leakage fromportions of the first substrate except at the pixel regions, an R/G/Bcolor filter layer for displaying various colors, and a common electrodefor producing an image. In an IPS mode LCD device, the common electrodeis formed on the first substrate, and an overcoat layer is formed on thesecond substrate.

When manufacturing the LCD devices, a plurality of LCD panels are formedon one mother substrate. That is, a plurality of LCD panel areas aredesigned in a first mother substrate, wherein each LCD panel areaincludes a thin film transistor array. Also, a plurality of LCD panelareas are designed in a second mother substrate, wherein each LCD panelarea includes a color filter array. Then, a sealant is formed in theperiphery of each LCD panel area formed on any one of the first andsecond mother substrates. Thereafter, the first and second mothersubstrates are bonded to each other, and the bonded substrates are cutinto the unit LCD panel areas, thereby manufacturing the LCD devices.

The method for manufacturing the LCD device is classified into a liquidcrystal injection method and a liquid crystal dispensing method.

In the liquid crystal injection method, the two substrates are bonded toeach other, and then the bonded substrates are cut into the unit LCDpanel areas. Thereafter, liquid crystal is injected to each LCD panel.Meanwhile, if applying the liquid crystal dispensing method, liquidcrystal is appropriately dispensed on each LCD panel area of the firstor second mother substrate, and then the first and second mothersubstrates are bonded to each other. Thereafter, the bonded substratesare cut into the unit LCD panels.

However, the liquid crystal injection method requires a long time forinjection of liquid crystal, and spends a lot of liquid crystal.Accordingly, the large-sized LCD device generally uses the liquidcrystal dispensing method. A method for manufacturing the LCD deviceaccording to the liquid crystal dispensing method will be explained asfollows.

FIG. 1 is a block diagram of a method for manufacturing an LCD deviceaccording to the related art.

First, a plurality of LCD panel areas are designed in first and secondmother substrates. Then, a thin film transistor array including a gateline, a data line, a thin film transistor, and a pixel region is formedin each LCD panel area of the first mother substrate (S11), and a firstalignment layer is formed on an entire surface of the first mothersubstrate, and a rubbing treatment is performed thereto (S12). Then, acolor filter array including a black matrix layer, a color filter layer,and a common electrode is formed in each LCD panel area of the secondmother substrate (S15), and a second alignment layer is formed on anentire surface of the second mother substrate, and a rubbing treatmentis performed thereto (S16).

In an IPS mode LCD device, a thin film transistor array including a gateline, a data line, a thin film transistor, a pixel region, and a commonelectrode is formed in each LCD panel area of the first mothersubstrate, and a color filter array including a black matrix layer, acolor filter layer, and an overcoat layer is formed in each LCD panelarea of the second mother substrate.

Then, the first and second mother substrates are cleaned (S13, S17). Thecleaned first mother substrate is loaded into a liquid crystal dispenser(LC dispenser), and liquid crystal is dispensed on the LCD panel areasof the first mother substrate (S14). Then, the cleaned second mothersubstrate is loaded into Ag and sealant dispensers, whereby Ag dots areformed on each LCD panel area (S18), and a sealant is formed in theperiphery of each LCD panel area (S19).

Thereafter, the first and second mother substrates are loaded into abonding apparatus, whereby the first and second mother substrates arebonded to each other. Then, the bonded first and second substrates areloaded into a curing apparatus, whereby the sealant is cured (S20).After that, the bonded first and second mother substrates having thecured sealant are loaded into a cutting apparatus, whereby thesubstrates are cut into the LCD panels (S21). Then, the cut LCD panelsare polished, and then is finally tested (S22). Although not shown, adriving circuit, a polarizing film, and a backlight are provided to eachLCD panel, thereby completing the LCD device.

On manufacturing the LCD panels, the efficiency of mother substratedepends on the arrangement of LCD panels having the various sizes(models) on the mother substrate. Also, since the LCD panel ismanufactured by the several steps, the size of the mother substrate islimited due to the size in each apparatus for manufacturing the LCDpanel.

Accordingly, after selecting the main model of the LCD panel, the layoutis designed based on the arrangement of the main models on the mothersubstrate. According to the design of layout, the optimal size of themother substrate is determined.

However, the efficient size of mother substrate, which can improves theefficiency of mother substrate in consideration of the layout forarranging the LCD panels, has not been proposed. Also, if arranging theplurality of LCD panels of the same size (model) on one mothersubstrate, the efficiency of mother substrate is lowered. This problembecomes more serious as the size of LCD panel becomes larger.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to a layout and a size ofa mother substrate in an LCD panel, which substantially obviates one ormore problems due to limitations and disadvantages of the related art.

An object of the present invention is to provide a layout of LCD panelsto improve the efficiency in arrangement of the LCD panels, and a sizeof the mother substrate to maximize the substrate efficiency.

Additional advantages, objects, and features of the invention will beset forth in part in the description which follows and in part willbecome apparent to those having ordinary skill in the art uponexamination of the following or may be learned from practice of theinvention. The objectives and other advantages of the invention may berealized and attained by the structure particularly pointed out in thewritten description and claims hereof as well as the appended drawings.

To achieve these objects and other advantages and in accordance with thepurpose of the invention, as embodied and broadly described herein, alayout of LCD panels comprises a mother substrate; a dummy region of 15mm or less in a periphery of the mother substrate; and six LCD panels ofthe 26-inch model in a matrix of 2×3 on the mother substrate excludingthe dummy region with a margin corresponding to 2˜4% of a length of theLCD panel.

In another aspect of the present invention, a substrate size comprises amother substrate having a size (M) which satisfiesM=(45.299L+43.805)˜(50.333L+48.673)×(51.509L+63.636)˜(57.232L+70.707)when arranging eight LCD panels of the same size, wherein ‘L’ is aninch-value of the LCD panel.

It is to be understood that both the foregoing general description andthe following detailed description of the present invention areexemplary and explanatory and are intended to provide furtherexplanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this application, illustrate embodiment(s) of the invention andtogether with the description serve to explain the principle of theinvention. In the drawings:

FIG. 1 is a block diagram of a method for manufacturing an LCD deviceaccording to the related art;

FIG. 2 is a table illustrating a substrate efficiency of 90% and 100%when arranging eight LCD panels on one mother substrate according to amodel of an LCD panel according to the present invention;

FIG. 3 is a graph illustrating a length change in the X-axis (minoraxis) of mother substrate from the table of FIG. 2;

FIG. 4 is a graph illustrating a length change in the Y-axis (majoraxis) of mother substrate from the table of FIG. 2;

FIG. 5 is a table illustrating a substrate efficiency of 90% and 100%when arranging six LCD panels on one mother substrate according to amodel of an LCD panel according to the present invention;

FIG. 6 is a graph illustrating a length change in the X-axis (minoraxis) of mother substrate from the table of FIG. 5;

FIG. 7 is a graph illustrating a length change in the Y-axis (majoraxis) of mother substrate from the table of FIG. 5;

FIGS. 8A to 8I are layouts illustrating the respective models on themother substrate having a size of 1100×1250 mm² according to the firstembodiment of the present invention;

FIG. 9 is a layout of arranging eight 26-inch models on the mothersubstrate having a size of 1300×1500 mm², according to the secondembodiment of the present invention;

FIGS. 10A to 10J are layouts illustrating the respective models on themother substrate having a size of 1500×1850 mm², according to the thirdembodiment of the present invention;

FIGS. 11A to 11S are layouts illustrating the respective models on themother substrate having a size of 1950×2250 mm², according to the fourthembodiment of the present invention;

FIGS. 12A to 12M are layouts illustrating the respective models on themother substrate having a size of 1870×2200 mm², according to the fifthembodiment of the present invention;

FIGS. 13A to 13G are layouts illustrating the respective models on themother substrate having a size of 2200×2500 mm², according to the sixthembodiment of the present invention; and

FIGS. 14A to 14J are layouts illustrating the respective models on themother substrate having a size of 2230×2600 mm², according to theseventh embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to embodiments of the presentinvention, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numbers will be usedthroughout the drawings to refer to the same or like parts.

Hereinafter, a layout of an LCD panel and a size of the mother substrateaccording to the present invention will be described with reference tothe accompanying drawings.

First, when designing a layout for arranging LCD panels of respectivemodels on a mother substrate, it is necessary to design the layout witha predetermined interval from an edge of the mother substrate (dummyregion, process key center, or exposure process region) and to secure amargin of each LCD panel, to thereby perform a uniformity in steps ofdeposition, exposure and etching, and to thereby obtain a peripheralexposure region.

That is, the size of the mother substrate is estimated with the dummyregion of 15 mm or less, and the length in each LCD panel including themargin of 0.3˜4% (the interval between the LCD panels, the intervalbetween the dummy region and the LCD panel, and the interval between theprocess key center and the exposure process region).

Under the conditions of the process according to the present invention,the margin of 20-inch or less LCD panels is about 2˜4%, the margin ofthe 30-inch LCD panels is about 1˜4%, and the margin of 50-inch LCDpanel is about 0.3˜4%. That is, as the LCD panel has the large size, thesize of the mother substrate increases, whereby the LCD panel can bemanufactured under the low margin of 0.3%.

According as the major or minor axis of the LCD panel corresponds to themajor axis of the mother substrate, the efficiency of mother substrateis variable. To improve the efficiency of mother substrate, it isnecessary to take the alignment relating the axes of the LCD panel andmother substrate into consideration.

In addition, a sealant for bonding two substrates to each other may haveeffects on the efficiency of mother substrate, which will be explainedas follows.

First, a black matrix layer of chrome (Cr), which is a heavy metalharmful to humans is formed on a substrate except pixel regions toprevent light leak age. In an IPS mode LCD device, which drives liquidcrystal with a transverse electric field induced between a pixelelectrode and a common electrode, if the black matrix layer is formed ofthe heavy metal, an electric field between the pixel electrode and thecommon electrode is distorted, and the black matrix layer of heavy metalis harmful to humans. Instead of a heavy metal, the black matrix layeris formed of carbon black, acryl comprising carbon black, epoxy orpolyimide resin.

In the IPS mode LCD device, a color filter array substrate includes theblack matrix layer described above, a color filter layer correspondingto each pixel region, and an overcoat layer on an entire surface of thesubstrate including the black matrix layer and the color filter layer.In a non-display area coated with a sealant, the black matrix layer ofresin and the overcoat layer are deposited.

Also, a thin film transistor array substrate is positioned at apredetermined cell gap with the color filter array substrate by spacersformed in a display area. However, in an area having the sealant, thesealant widely spreads due to bonding pressure, whereby the cell gap ischanged. Accordingly, it is necessary to additionally provide supportersmade of glass fiber or glass balls to the sealant, to thereby preventthe cell gap from being changed.

If the two substrates are bonded to each other such that the sealanthaving the supporter is formed on the overcoat layer and is overlappedwith the black matrix layer, the black matrix layer of resin and theovercoat layer are depressed due to the glass fiber or glass ballincluded in the sealant by a bonding pressure. As the supporter includedin the sealant depresses the black matrix layer of resin and theovercoat layer, the sealant may be deformed.

To prevent the deformation of sealant, it is necessary that the sealantdoes not overlapped with the black matrix layer. However, if the sealantis not overlapped with the black matrix layer, a dummy region of the LCDdevice increases in size, thereby causing the decrease in the efficiencyof the substrate. To optimize the ratio of supporter included in thesealant, the sealant is overlapped with the black matrix layer, wherebythe size of dummy region of the LCD device decreases, to therebyoptimize the efficiency of substrate.

That is, the supporter made of glass fibers or glass balls is providedin the sealant at a weight ratio of 1% or less. For example, if thesupporter includes glass balls, five-hundred or fewer glass balls areprovided in the unit area of 1 mm×1 mm of the sealant. If the supporterincludes glass fibers, one-hundred fifty glass fibers are provided inthe unit area of 1 mm×1 mm of the sealant. In other words, if the weightratio of supporter corresponds to about 0.95%˜0.005% of the sealant, itis possible to prevent the deformation of sealant even thought thesealant is overlapped with the black matrix layer, thereby improving theefficiency of substrate.

The other element for preventing the deformation of sealant when thesealant is overlapped with the black matrix layer is the thickness ofthe overcoat layer. That is, if the supporter such as the glass fiber orglass ball is added to the sealant at the weight ratio of 1% or less,and the thickness of the overcoat layer is determined between 1.2 μm and5 μm, it is possible to prevent the deformation of sealant. That is, ifforming the overcoat layer with a thickness between 1.2 μm and 5 μm, itis possible to prevent the black matrix layer from being depressed.

For example, when designing the 20.1-inch LCD panel on the glasssubstrate having a size of 1870×2200 mm, the dummy region of the LCDpanel increases so as not to overlap the sealant with the black matrixlayer, making it possible to provide twenty four LCD panels on thesubstrate at maximum. However, if the sealant is overlapped with theblack matrix layer by optimizing the weight ratio of supporter includedin the sealant, it is possible to decrease the dummy region of the LCDpanel, thereby providing thirty LCD panels on the substrate at maximum.As a result, it is possible to maximize the efficiency of substrate byoptimizing the weight ratio of supporter included in the sealant, or bycontrolling the thickness of the overcoat layer.

When providing eight LCD panels on the mother substrate according to themodel of the LCD panel under the above conditions of the dummy region,the margin, the weight ratio of supporter included in the sealant, andthe thickness of the overcoat layer, the size of substrate is explainedas follows, as realizing the substrate efficiency of 90% or more.

FIG. 2 is a table illustrating a substrate efficiency of 90% and 100%when arranging eight LCD panels on one mother substrate according to amodel of an LCD panel according to the present invention. FIG. 3 is agraph illustrating a length change in the X-axis (minor axis) of mothersubstrate from the table of FIG. 2.

First, if arranging eight LCD panels of the 23-inch model (23WX, pictureratio of 16:9, IPS mode, diagonal length of 22.95-inch, panel size of523.7×302.7 mm²) under the above margin conditions, the size of themother substrate corresponds to 1206×1387 mm² when the substrateefficiency is 90%, and the size of the mother substrate corresponds to1085×1248 mm² when the substrate efficiency is 100%. Accordingly, ifarranging eight LCD panels of a 23-inch model, the size of the mothersubstrate satisfies 1085˜1206×1248˜1387 mm² to achieve the substrateefficiency of 90% or more.

First, if arranging eight LCD panels of the 23-inch model (23WX, pictureratio of 16:9, IPS mode, diagonal length of 22.95-inch, panel size of523.7×302.7 mm²) under the above margin conditions, the size of themother substrate corresponds to 1206×1387 mm² when the substrateefficiency is 90%, and the size of the mother substrate corresponds to1085×1248 mm² when the substrate efficiency is 100%. Specifically,1085/1206=90% and 1248/1387=90%. Accordingly, if arranging eight LCDpanels of a 23-inch model, the size of the mother substrate satisfies1085˜1206×1248˜1387 mm² to achieve the substrate efficiency of 90% ormore.

If arranging eight LCD panels of a 26-inch model (26WX, picture ratio of16:9, IPS mode, diagonal length of the 26-inch, panel size of590.9×341.5 mm²) under the above margin conditions, the size of themother substrate corresponds to 1353×1555 mm² when the substrateefficiency is 90%, and the size of the mother substrate corresponds to1218×1399 mm² when the substrate efficiency is 100%. Accordingly, ifarranging eight LCD panels of a 26-inch model, the size of the mothersubstrate satisfies 1218˜1353×1399˜1555 mm² to achieve the substrateefficiency of 90% or more.

If arranging eight LCD panels of a 32-inch model (32WX, picture ratio of16:9, IPS mode, diagonal length of 31.5-inch, panel size of 715.0×413.05mm²) under the above margin conditions, the size of the mother substratecorresponds to 1630×1873 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 1467×1686 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging eight LCD panelsof a 32-inch model, the size of the mother substrate satisfies1467˜1630×1686˜1873 mm² to achieve the substrate efficiency of 90% ormore.

If arranging eight LCD panels of a 37-inch model (37WU, picture ratio of16:9, IPS mode, diagonal length of 37.0-inch, panel size of 846.0×485.2mm²) under the above margin conditions, the size of the mother substratecorresponds to 1923×2195 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 1730×1976 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging eight LCD panelsof a 37-inch model, the size of the mother substrate satisfies1730˜1923×1976˜2195 mm² to achieve the substrate efficiency of 90% ormore.

If arranging eight LCD panels of a 40-inch model (40WU, picture ratio of16:9, IPS mode, diagonal length of 39.8-inch, panel size of 906.2×521.4mm²) under the above margin conditions, the size of the mother substratecorresponds to 2057×2356 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 1851×2121 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging eight LCD panelsof a 40-inch model, the size of the mother substrate satisfies1851˜2057×2121˜2356 mm² to achieve the substrate efficiency of 90% ormore.

If arranging eight LCD panels of a 42-inch model (42WU, picture ratio of16:9, IPS mode, diagonal length of the 42-inch, panel size of956.0×549.0 mm²) under the above margin conditions, the size of themother substrate corresponds to 2168×2479 mm² when the substrateefficiency is 90%, and the size of the mother substrate corresponds to1952×2231 mm² when the substrate efficiency is 100%. Accordingly, ifarranging eight LCD panels of a 42-inch model, the size of the mothersubstrate satisfies 1952˜2168×2231˜2479 mm² to achieve the substrateefficiency of 90% or more.

If arranging eight LCD panels of a 46-inch model (46WU, picture ratio of16:9, IPS mode, diagonal length of 46.1-inch, panel size of 1043.0×600.5mm²) under the above margin conditions, the size of the mother substratecorresponds to 2363×2709 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 2126×2438 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging eight LCD panelsof a 46-inch model, the size of the mother substrate satisfies2126˜2363×2438˜2709 mm² to achieve the substrate efficiency of 90% ormore.

If arranging eight LCD panels of a 47-inch model (47WU, picture ratio of16:9, IPS mode, diagonal length of the 47-inch, panel size of 1065×610.5mm²) under the above margin conditions, the size of the mother substratecorresponds to 2412×2753 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 2171×2478 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging eight LCD panelsof a 47-inch model, the size of the mother substrate satisfies2171˜2412×2478˜2753 mm² to achieve the substrate efficiency of 90% ormore.

If arranging eight LCD panels of a 57-inch model (57WU, picture ratio of16:9, IPS mode, diagonal length of 56.7-inch, panel size of 1276.2×727.2mm²) under the above margin conditions, the size of the mother substratecorresponds to 2884×3273 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 2595×2946 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging eight LCD panelsof a 57-inch model, the size of the mother substrate satisfies2595˜2884×2946 ˜3273 mm² to achieve the substrate efficiency of 90% ormore.

Referring to FIG. 2, if arranging eight LCD panels of the other model,it is possible to estimate the size of the mother substrate forrealization of substrate efficiency of 90% or more.

FIG. 3 is a graph illustrating a length change in the X-axis (minoraxis) of mother substrate from the table of FIG. 2. FIG. 4 is a graphillustrating a length change in the Y-axis (major axis) of mothersubstrate from the table of FIG. 2. As illustrated in FIGS. 3 and 4, ifshowing the substrate efficiency for each size by graph, it is close toa straight line (linear equation, R²=0.9998 or R²=0.9997), which isexpressed as follows.

First, the length (X, mm) of the minor axis of the mother substrate canbe expressed as the size (virtual diagonal length, inch, L) of each LCDpanel.X=50.333L+48.673  [equation 1]The above [equation 1] illustrates the length (X) of the minor axis whenthe eight LCD panels of each model are arranged on the mother substrate,and the substrate efficiency is 90%.X=45.299L+43.805  [equation 2]The above [equation 2] illustrates the length (X) of the minor axis whenthe eight LCD panels of each model are arranged on the mother substrate,and the substrate efficiency is 100%.

Also, the length (Y, mm) of the major axis of the mother substrate canbe expressed as the size (virtual diagonal length, inch, L) of each LCDpanel.Y=57.232L+70.707  [equation 3]The above [equation 3] illustrates the length (Y) of the major axis whenthe eight LCD panels of each model are arranged on the mother substrate,and the substrate efficiency is 90%.Y=51.509L+63.636  [equation 4]The above [equation 4] illustrates the length (Y) of the major axis whenthe eight LCD panels of each model are arranged on the mother substrate,and the substrate efficiency is 100%.

Based on the above [equation 1], [equation 2], [equation 3] and[equation 4], when the eight LCD panels for each model are arranged onthe mother substrate, and the substrate efficiency is 90% or more, thesize (M) of mother substrate is expressed as the following [equation 5].M=(45.299L+43.805)˜(50.333L+48.673)×(51.509L+63.636)˜(57.232L+70.707)  [equation5]

For example, in the 26-inch model LCD panel, the virtual diagonal length(L) is 26 inch. If applying the virtual diagonal length (L) of 26 inchto the above [equation 5], the size (M) of mother substrate is1221.579˜1357.331×1404.976˜1558.739. This value is very similar to thevalue from the table of FIG. 2.

When providing six LCD panels on the mother substrate according to themodel of the LCD panel under the above conditions of the dummy region,the margin, the weight ratio of supporter included in the sealant, andthe thickness of the overcoat layer, the size of substrate is explainedas follows, as realizing the substrate efficiency of 90% or more.

FIG. 5 is a table illustrating a substrate efficiency of 90% and 100%when arranging six LCD panels on one mother substrate according to amodel of an LCD panel according to the present invention. FIG. 6 is agraph illustrating a length change in the X-axis (minor axis) of mothersubstrate from the table of FIG. 5. FIG. 7 is a graph illustrating alength change in the Y-axis (major axis) of mother substrate from thetable of FIG. 5.

First, if arranging six LCD panels of the 23-inch model, the size of themother substrate satisfies 994˜1049×1085˜1206 mm² to achieve thesubstrate efficiency of 90% or more.

If arranging six LCD panels of a 26-inch model (26WX, picture ratio of16:9, IPS mode, diagonal length of the 26-inch, panel size of590.9×341.5 mm²) under the above margin conditions, the size of themother substrate corresponds to 1175×1353 mm² when the substrateefficiency is 90%, and the size of the mother substrate corresponds to1058×1218 mm² when the substrate efficiency is 100%. Accordingly, ifarranging six LCD panels of a 26-inch model, the size of the mothersubstrate satisfies 1058˜1175×1218˜1353 mm² to achieve the substrateefficiency of 90% or more.

If arranging six LCD panels of a 32-inch model (32WX, picture ratio of16:9, IPS mode, diagonal length of 31.5-inch, panel size of 715.0×413.05mm²) under the above margin conditions, the size of the mother substratecorresponds to 1415×1630 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 1273×1467 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging six LCD panelsof a 32-inch model, the size of the mother substrate satisfies1273˜1415×1467˜1630 mm² to achieve the substrate efficiency of 90% ormore.

If arranging six LCD panels of a 37-inch model (37WU, picture ratio of16:9, IPS mode, diagonal length of 37.0-inch, panel size of 846.0×485.2mm²) under the above margin conditions, the size of the mother substratecorresponds to 1656×1923 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 1490×1730 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging six LCD panelsof a 37-inch model, the size of the mother substrate satisfies1490˜1656×1730˜1923 mm² to achieve the substrate efficiency of 90% ormore.

If arranging six LCD panels of a 40-inch model (40WU, picture ratio of16:9, IPS mode, diagonal length of 39.8-inch, panel size of 906.2×521.4mm²) under the above margin conditions, the size of the mother substratecorresponds to 1777×2057 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 1599×1851 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging six LCD panelsof a 40-inch model, the size of the mother substrate satisfies1599˜1777×1851˜2057 mm² to achieve the substrate efficiency of 90% ormore.

If arranging six LCD panels of a 42-inch model (42WU, picture ratio of16:9, IPS mode, diagonal length of the 42-inch, panel size of956.0×549.0 mm²) under the above margin conditions, the size of themother substrate corresponds to 1869×2168 mm² when the substrateefficiency is 90%, and the size of the mother substrate corresponds to1682×1952 mm² when the substrate efficiency is 100%. Accordingly, ifarranging six LCD panels of a 42-inch model, the size of the mothersubstrate satisfies 1682˜1869×1952˜2168 mm² to achieve the substrateefficiency of 90% or more.

If arranging six LCD panels of a 46-inch model (46WU, picture ratio of16:9, IPS mode, diagonal length of 46.1-inch, panel size of 1043.0×600.5mm²) under the above margin conditions, the size of the mother substratecorresponds to 2042×2363 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 1838×2126 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging six LCD panelsof a 46-inch model, the size of the mother substrate satisfies1838˜2042×2126˜2363 mm² to achieve the substrate efficiency of 90% ormore.

If arranging six LCD panels of a 47-inch model (47WU, picture ratio of16:9, IPS mode, diagonal length of the 47-inch, panel size of1065.0×610.5 mm²) under the above margin conditions, the size of themother substrate corresponds to 2075×2412 mm² when the substrateefficiency is 90%, and the size of the mother substrate corresponds to1868×2171 mm² when the substrate efficiency is 100%. Accordingly, ifarranging six LCD panels of a 47-inch model, the size of the mothersubstrate satisfies 1868˜2075×2171˜2412 mm² to achieve the substrateefficiency of 90% or more.

If arranging six LCD panels of a 49-inch mode¹ (49WU, picture ratio of16:9, IPS mode, diagonal length of 49-inch, panel size of 1115.6×640.9mm²) under the above margin conditions, the size of the mother substratecorresponds to 2177×2525 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 1959×2272 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging six LCD panelshaving 49-inch model, the size of the mother substrate satisfies1959˜2177×2272˜2525 mm² to achieve the substrate efficiency of 90% ormore.

If arranging six LCD panels of a 50-inch model (50WU, picture ratio of16:9, IPS mode, diagonal length of 49.7-inch, panel size of 1127.5×646.5mm²) under the above margin conditions, the size of the mother substratecorresponds to 2196×2551 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 1976×2296 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging six LCD panelsof a 50-inch model, the size of the mother substrate satisfies1976˜2196×2296˜2551 mm² to achieve the substrate efficiency of 90% ormore.

If arranging six LCD panels of a 52-inch model (52WU, picture ratio of16:9, IPS mode, diagonal length of the 52-inch, panel size of1174.5×670.5 mm²) under the above margin conditions, the size of themother substrate corresponds to 2276×2656 mm² when the substrateefficiency is 90%, and the size of the mother substrate corresponds to2048×2391 mm² when the substrate efficiency is 100%. Accordingly, ifarranging six LCD panels having 52-inch model, the size of the mothersubstrate satisfies 2048˜2276×2391˜2656 mm² to achieve the substrateefficiency of 90% or more.

If arranging six LCD panels of a 55-inch model (55WU, picture ratio of16:9, IPS mode, diagonal length of 54.6-inch, panel size of 1233.0×710.0mm²) under the above margin conditions, the size of the mother substratecorresponds to 2408×2787 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 2167×2508 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging six LCD panelsof a 55-inch model, the size of the mother substrate satisfies2167˜2408×2508˜2787 mm² to achieve the substrate efficiency of 90% ormore.

If arranging six LCD panels of a 57-inch model (57WU, picture ratio of16:9, IPS mode, diagonal length of 56.7-inch, panel size of 1276.2×727.2mm²) under the above margin conditions, the size of the mother substratecorresponds to 2465×2884 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 2219×2595 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging six LCD panelsof a 57-inch model, the size of the mother substrate satisfies2219˜2465×2595˜2884 mm² to achieve the substrate efficiency of 90% ormore.

If arranging six LCD panels of a 65-inch model (65WU, picture ratio of16:9, IPS mode, diagonal length of 65.0-inch, panel size of 1476.0×846.0mm²) under the above margin conditions, the size of the mother substratecorresponds to 2863×3330 mm² when the substrate efficiency is 90%, andthe size of the mother substrate corresponds to 2576×2997 mm² when thesubstrate efficiency is 100%. Accordingly, if arranging six LCD panelshaving 65-inch model, the size of the mother substrate satisfies2576˜2863×2997˜3330 mm² to achieve the substrate efficiency of 90% ormore.

Referring to FIG. 6, if arranging six LCD panels of another model, it ispossible to estimate the size of the mother substrate for realization ofsubstrate efficiency of 90% or more.

FIG. 6 is a graph illustrating a length change in the X-axis (minoraxis) of mother substrate from the table of FIG. 5. FIG. 7 is a graphillustrating a length change in the Y-axis (major axis) of mothersubstrate from the table of FIG. 5.

As illustrated in FIGS. 6 and 7, if showing the substrate efficiency foreach size by graph, it is close to a straight line (linear equation,R²=0.9998 or R²=0.9997), which is expressed as follows.

First, the length (X, mm) of the minor axis of the mother substrate canbe expressed as the size (virtual diagonal length, inch, L) of each LCDpanel.X=42.96L+61.387  [equation 6]The above [equation 6] illustrates the length (X) of the minor axis whenthe six LCD panels of each model are arranged on the mother substrate,and the substrate efficiency is 90%.X=38.664L+55.248  [equation 7]The above [equation 7] illustrates the length (X) of the minor axis whenthe six LCD panels of each model are arranged on the mother substrate,and the substrate efficiency is 100%.

Also, the length (Y, mm) of the major axis of the mother substrate canbe expressed as the size (virtual diagonal length, inch, L) of each LCDpanel.Y=50.333L+48.673  [equation 8]The above [equation 8] illustrates the length (Y) of the major axis whenthe six LCD panels of each model are arranged on the mother substrate,and the substrate efficiency is 90%.Y=45.299L+43.805  [equation 9]The above [equation 9] illustrates the length (Y) of the major axis whenthe six LCD panels of each model are arranged on the mother substrate,and the substrate efficiency is 100%.

Based on the above [equation 6], [equation 7], [equation 8] and[equation 9], when the six LCD panels for each model are arranged on themother substrate, and the substrate efficiency is 90% or more, the size(M) of mother substrate is expressed as the following [equation 10].M=(38.664L+55.248)˜(42.96L+61.387)×(45.299L+43.805)˜(50.333L+48.673)  [equation10]

For example, in the model of LCD panel of the 52-inch wide, the virtualdiagonal length (L) is 52 inch. If applying the virtual diagonal length(L) of 52 inch to the above [equation 10], the size (M) of mothersubstrate is 2065.776˜2295.307×2399.353˜2665.989. This value is verysimilar to the value from the table of FIG. 5.

In FIGS. 2 to 7, the model mode of IPS or TN is explained. However, itis not limited to these modes. For example, without regard to the modelmode of VA, OCB, ECB or FLCD, it is possible to estimate the optimalsize of the mother substrate corresponding to the inch of LCD panel. Inaddition to the above-mentioned picture ratios, various picture ratiosof 16:10, 4:3, 5:4, etc. can be used.

As described above, arranging the six LCD panels of the 26-inch modelhas a similar size mother substrate as arranging the eight LCD panels ofthe 23-inch model. That is, the size of the mother substrate satisfies1085˜1206×1248˜1387 mm² when arranging the eight LCD panels of the23-inch model for realization of substrate efficiency of 90% or more,and the size of the mother substrate satisfies 1058˜1175×1218˜1353 mm²when arranging the six LCD panels of the 26-inch model for realizationof substrate efficiency of 90% or more. In the above conditions relatingthe size of mother substrate, the optimal size of the mother substrateis 100×1250 mm².

The layout of the cases for arranging the eight LCD panels of the23-inch model on the mother substrate (1100×1250 mm²) and arranging thesix LCD panels of the 26-inch model on the mother substrate (1100×1250mm²) will be explained as follows. FIGS. 8A to 8I are layoutsillustrating the respective models on the mother substrate having a sizeof 1100×1250 mm², according to the first embodiment of the presentinvention.

FIG. 8A illustrates the layout of arranging six LCD panels (2 column×3row) of the 26-inch model (26WX, picture ratio of 16:9, IPS mode,virtual diagonal length of the 26-inch, panel size of 590.9×341.5 mm²)on the mother substrate having a size of 1100×1250 mm². That is, thedummy region is 15 mm, and the margin is 2˜4% of the length of LCDpanel. The process key center (1) is provided at the interval of 15 mmfrom the edge of the mother substrate in the direction of major axis,and the dummy region (2) is provided at the interval of 15 mm from theedge of the mother substrate in the direction of minor axis. The six LCDpanels of the 26-inch model are arranged in a matrix (2 column×3 row) inthe margin of 11.4 mm from the process key center (1), and in the marginof 12.7 mm from the dummy region (2), wherein the margin between eachcolumn is 12.7 mm, and the margin between each row is 11.4 mm.

In FIG. 8A, the six LCD panels of the 26-inch model are arranged in thematrix type (2 column×3 row), and the major axis of the LCD panelcorresponds to the major axis of the mother substrate. Also, the marginvalue is not limited to the above description, which can be controllablewithin ±30%. According to the above arrangement of LCD panels on themother substrate, it is possible To achieve substrate efficiency of 90%or more.

FIG. 8B illustrates the layout of arranging eight LCD panels (4 column×2row) of the 23-inch model (23WX, picture ratio of 16:9, IPS mode,virtual diagonal length of 22.95-inch, panel size of 523.7×302.7 mm²) onthe mother substrate having a size of 1100×1250 mm². That is, the dummyregion is 10 mm, and the margin is 1% of the length of LCD panel. Theprocess key center (1) is provided at the interval of 14 mm from theedge of the mother substrate in the direction of major axis, and thedummy region (2) is provided at the interval of 10 mm from the edge ofthe mother substrate in the direction of minor axis. The eight LCDpanels of the 23-inch model are arranged in a matrix (4 column×2 row) inthe margin of 6 mm from the process key center (1), and in the margin of2.85 mm from the dummy region (2), wherein the margin between eachcolumn is 4.5 mm, and the margin between each row is 12.6 mm.

In FIG. 8B, the eight LCD panels of the 23-inch model are arranged inthe matrix type (4 column×2 row), and the major axis of the LCD panelcorresponds to the minor axis of the mother substrate. Also, the marginvalue is not limited to the above description, which can be controllablewithin ±30%. According to the above arrangement of LCD panels on themother substrate, it is possible To achieve substrate efficiency of 90%or more.

FIG. 8C illustrates the layout of arranging six LCD panels (2 column×3row) of the 24-inch model (24WU, picture ratio of 16:9, IPS mode,virtual diagonal length of 23.93-inch, panel size of 529×336 mm²) on themother substrate having a size of 1100×1250 mm². That is, the six LCDpanels of the 24-inch model are arranged in a matrix (2 column×3 row) inthe similar margin above mentioned, wherein the major axis of the LCDpanel corresponds to the major axis of the mother substrate.

FIG. 8D illustrates the layout of arranging twelve LCD panels (4column×3 row) of the 17-inch model (17SX, picture ratio of 5:4, TN mode,virtual diagonal length of 17.04-inch, panel size of 347×278.9 mm²) onthe mother substrate having a size of 1100×1250 mm², and arranging sixLCD panels of 7-inch wide mode (7X, picture ratio of 16:9, TN mode,panel size of 162.7×90.2 mm²) on the mother substrate. If arranging onlythe twelve LCD panels of the 17-inch wide mode, the substrate efficiencyis below 90%. However, according as the six LCD panels of 7-inch widemode are additionally formed on the mother substrate, it is possible Toachieve substrate efficiency of 90% or more. That is, the twelve LCDpanels of the 17-inch wide mode are arranged as the matrix (4 column×3row) in the similar margin above mentioned, and the six LCD panels of7-inch wide mode are arranged as one column, wherein the major axis ofthe LCD panel corresponds to the minor axis of the mother substrate.

FIG. 8E illustrates the layout of arranging fifteen LCD panels (5column×3 row) of the 15-inch model (15X, picture ratio of 3:4, TN mode,virtual diagonal length of 14.97-inch, panel size of 312.2×235.6 mm²) onthe mother substrate having a size of 1100×1250 mm². That is, thefifteen LCD panels of the 15-inch model are arranged in a matrix (5column×3 row) in the similar margin above mentioned, wherein the majoraxis of the LCD panel corresponds to the minor axis of the mothersubstrate.

FIG. 8F illustrates the layout of arranging twenty four LCD panels (6column×4 row) of the 12.1-inch model for notebook computers (12.1XGA,picture ratio of 3:4, TN mode, panel size of 254.5×192.6 mm²) on themother substrate having a size of 1100×1250 mm². That is, the twentyfour LCD panels of the 12.1-inch model are arranged in a matrix (6column×4 row) in the similar margin above mentioned, wherein the majoraxis of the LCD panel corresponds to the minor axis of the mothersubstrate.

FIG. 8G illustrates the layout of arranging eight LCD panels (4 column×2row) of the 22-inch model (22WSX) for monitors on the mother substratehaving a size of 1100×1250 mm². That is, the eight LCD panels of the22-inch model are arranged in a matrix (4 column×2 row) in the similarmargin above mentioned, wherein the major axis of the LCD panelcorresponds to the minor axis of the mother substrate.

FIG. 8H illustrates the layout of arranging twelve LCD panels (4column×3 row) of the 18-inch model for monitors (18WX, picture ratio of16:10, TN mode) on the mother substrate having a size of 1100×1250 mm².That is, the twelve LCD panels of the 18-inch model are arranged in amatrix (4 column×3 row) in the similar margin above mentioned, whereinthe major axis of the LCD panel corresponds to the major axis of themother substrate.

FIG. 8I illustrates the layout of arranging eighteen LCD panels (6column×3 row) of the 14.1-inch model (14.1W, picture ratio of 16:10, TNmode, virtual diagonal length of 14.08-inch, panel size of 311.74×197.44mm²) on the mother substrate having a size of 1100×1250 mm², andarranging twelve LCD panels of the 4-inch model (picture ratio of 3:4,TN mode, panel size of 91.6×71.2 mm²) on the mother substrate. That is,the eighteen LCD panels of the 14.1-inch model are arranged in a matrix(6 column×3 row) in the similar margin above mentioned, wherein themajor axis of the LCD panel corresponds to the minor axis of the mothersubstrate. In addition, the twelve LCD panels of the 4-inch model arearranged on the mother substrate along one row. In this case, the LCDpanels of the 14.1-inch model are arranged at the small interval.

In FIGS. 2 to 4, if arranging the eight LCD panels of the 26-inch model(26WX, picture ratio of 16:9, IPS mode, virtual diagonal length of26.0-inch, panel size of 590.9×341.5 mm²), the size of the mothersubstrate satisfies 1218˜1353×1399˜1555 mm² for realization of substrateefficiency of 90% or more. The optimal size of the mother substratecorresponds to 1300×1500 mm².

FIG. 9 is a layout of arranging eight 26-inch models on the mothersubstrate having a size of 1300×1500 mm², according to the secondembodiment of the present invention.

That is, as illustrated in FIG. 9, the dummy region is 15 mm, and themargin is 0.3˜5% of the length of LCD panel. The process key center (1)is provided at the interval of 14 mm from the edge of the mothersubstrate in the direction of major axis, and the dummy region (2) isprovided at the interval of 15 mm from the edge of the mother substratein the direction of minor axis. The eight LCD panels of the 26-inchmodel are arranged in a matrix (4 column×2 row) in the margin of 20 mmfrom the process key center (1), and in the margin of 20.5 mm from thedummy region (2), wherein the margin between each column is 21 mm, andthe margin between each row is 50.2 mm. In FIG. 9, the LCD panels of the26-inch model are arranged in a matrix (4 column×2 row), and the majoraxis of the LCD panel corresponds to the minor axis of the mothersubstrate.

As explained above, arranging the eight LCD panels of the 32-inch modelhas a similar size mother substrate as arranging the six LCD panels ofthe 37-inch model. To achieve substrate efficiency of 90% or more, thesize of the mother substrate satisfies 1467˜1630×1686˜1873 mm² whenarranging the eight LCD panels of the 32-inch wide mode, and the size ofthe mother substrate satisfies 1490˜1656×1730˜1923 mm² when arrangingthe six LCD panels of the 37-inch model.

In the above conditions relating the size of mother substrate, theoptimal size of the mother substrate is 1500×1850 mm².

The layout of the cases for arranging the eight LCD panels of the32-inch model on the mother substrate (1500×1850 mm²) and arranging thesix LCD panels of the 37-inch model on the mother substrate (1500×1850mm²) will be explained as follows. FIGS. 10A to 10J are layoutsillustrating the respective models on the mother substrate having a sizeof 1500×1850 mm², according to the third embodiment of the presentinvention.

FIG. 10A illustrates the layout of arranging eight LCD panels (4column×2 row) of the 32-inch model (32WX, picture ratio of 16:9, IPSmode, virtual diagonal length of 31.5-inch, panel size of 715.0×413.05mm²) on the mother substrate having a size of 1500×1850 mm². That is,the dummy region is 15 mm, and the margin is 0.3˜5% of the length of LCDpanel. The process key center (1) is provided at the interval of 14 mmfrom the edge of the mother substrate in the direction of major axis,and the dummy region (2) is provided at the interval of 15 mm from theedge of the mother substrate in the direction of minor axis. The eightLCD panels of the 32-inch model are arranged in a matrix (4 column×2row) in the margin of 11 mm from the process key center (1), and in themargin of 31.4 mm from the dummy region (2), wherein the margin betweeneach column is 35 mm, and the margin between each row is 20 mm. In FIG.10A the eight LCD panels of the 32-inch model are arranged in the matrixtype (4 column×2 row), and the major axis of the LCD panel correspondsto the minor axis of the mother substrate.

FIG. 10B illustrates the layout of arranging six LCD panels (2 column×3row) of the 37-inch model (37WU, picture ratio of 16:9, IPS mode,virtual diagonal length of 37.0-inch, panel size of 846.0×485.2 mm²) onthe mother substrate having a size of 1500×1850 mm². That is, the dummyregion is 15 mm, and the margin is 0.3˜5% of the length of LCD panel.The process key center (1) is provided at the interval of 14 mm from theedge of the mother substrate in the direction of major axis, and thedummy region (2) is provided at the interval of 15 mm from the edge ofthe mother substrate in the direction of minor axis. The six LCD panelsof the 37-inch model are arranged in a matrix (2 column×3 row) in themargin of 3.2 mm from the process key center (1), and in the margin of34 mm from the dummy region (2), wherein the margin between each columnis 60 mm, and the margin between each row is 5 mm. In FIG. 10B, the sixLCD panels of the 37-inch model are arranged in the matrix type (2column×3 row), and the major axis of the LCD panel corresponds to themajor axis of the mother substrate.

FIG. 10C illustrates the layout of arranging eighteen LCD panels (6column×3 row) of the 20.1-inch model for monitors (20.1WSX, pictureratio of 16:9, IPS mode) on the mother substrate having a size of500×1850 mm². That is, the eighteen LCD panels of the 20.1-inch modelare arranged in a matrix (6 column×3 row) in the similar margin abovementioned, wherein the major axis of the LCD panel corresponds to theminor axis of the mother substrate.

FIG. 10D illustrates the layout of arranging sixteen LCD panels (4column×4 row) of the 20.1-inch model for monitors (20.1X, picture ratioof 3:4, IPS mode, virtual diagonal length of 20.08-inch, panel size of422.5×317.5 mm²) on the mother substrate having a size of 1500×1850 mm².That is, the sixteen LCD panels of the 20.1-inch model are arranged in amatrix (4 column×4 row) in the similar margin above mentioned, whereinthe major axis of the LCD panel corresponds to the major axis of themother substrate.

FIG. 10E illustrates the layout of arranging eighteen LCD panels (6column×3 row) of the 17-inch model (17SX, picture ratio of 5:4, TN mode,virtual diagonal length of 17.04-inch, panel size of 347×278.9 mm²) onthe mother substrate having a size of 1500×1850 mm². That is, theeighteen LCD panels of the 17-inch model are arranged in a matrix (6column×3 row) in the similar margin above mentioned, wherein the majoraxis of the LCD panel corresponds to the minor axis of the mothersubstrate.

FIG. 10F illustrates the layout of arranging eight LCD panels (4column×2 row) of the 30-inch model (30WQX, picture ratio of 16:10, IPSmode, virtual diagonal length of 29.95-inch, panel size of 661×419 mm²)on the mother substrate having a size of 1500×1850 mm². That is, theeight LCD panels of the 30-inch model are arranged in a matrix (4column×2 row) in the similar margin above mentioned, wherein the majoraxis of the LCD panel corresponds to the minor axis of the mothersubstrate.

FIG. 10G illustrates the layout of arranging twenty four LCD panels (6column×4 row) of the 17-inch model (17SX, picture ratio of 5:4, TN mode,virtual diagonal length of 17.04-inch, panel size of 347×278.9 mm²) onthe mother substrate having a size of 1500×1850 mm², and arranging sixLCD panels of 8-inch model (8W, picture ratio of 16:9, IPS mode, panelsize of 191.6×115.2 mm²) on the mother substrate. That is, the twentyfour LCD panels of the 17-inch model are arranged in a matrix (6column×4 row) in the similar margin above mentioned, wherein the majoraxis of the LCD panel corresponds to the minor axis of the mothersubstrate. In addition, the six LCD panels of 8-inch model are arrangedas one row.

FIG. 10H illustrates the layout of arranging eighteen LCD panels (6column×3 row) of 20-inch model (20WSX, picture ratio of 16:9, TN mode,panel size of 452.584×258.832 mm²) on the mother substrate having a sizeof 1500×1850 mm². That is, the eighteen LCD panels of the 20-inch modelare arranged in a matrix (6 column×3 row) in the similar margin abovementioned, wherein the major axis of the LCD panel corresponds to theminor axis of the mother substrate.

FIG. 10I illustrates the layout of arranging twelve LCD panels (4column×3 row) of the 26-inch model (26WX, picture ratio of 16:9, IPSmode, virtual diagonal length of 26.0-inch, panel size of 590.9×341.5mm²) on the mother substrate having a size of 1500×1850 mm². That is,the twelve LCD panels of the 26-inch model are arranged in a matrix (4column×3 row) in the similar margin above mentioned, wherein the majoraxis of the LCD panel corresponds to the major axis of the mothersubstrate.

FIG. 10J illustrates the layout of arranging three LCD panels (3column×1 row) of the 42-inch model (42WU, picture ratio of 16:9, IPSmode, virtual diagonal length of the 42-inch, panel size of 956.0×549.0mm²) on the mother substrate having a size of 1500×1850 mm², andarranging six LCD panels (6 column×1 row) of the 20.1-inch model(20.1WSX, picture ratio of 16:9, IPS mode) on the mother substrate. Thatis, the three LCD panels of the 42-inch model are arranged in a matrix(3 column×1 row) in the similar margin above mentioned, wherein themajor axis of the LCD panel corresponds to the minor axis of the mothersubstrate. In addition, the six LCD panels of the 20.1-inch model arearranged as one row on the mother substrate.

In addition, arranging the eight LCD panels of the 42-inch model has asimilar size mother substrate as arranging the six LCD panels of the47-inch model. To achieve substrate efficiency of 90% or more, the sizeof the mother substrate satisfies 1952˜2168×2231˜2479 mm² when arrangingthe eight LCD panels of the 42-inch model, and the size of the mothersubstrate satisfies 1868˜2075×2171˜2412 mm² when arranging the six LCDpanels of the 47-inch model. Under these conditions, the optimal size ofthe mother substrate satisfying the above two cases is 1950×2250 mm².

The layout of cases for arranging eight LCD panels of the 42-inch modelon the mother substrate (1950×2250 mm²) and arranging six LCD panels ofthe 47-inch model on the mother substrate (1950×2250 mm²) will beexplained as follows. FIGS. 11A to 11S are layouts illustrating therespective models on the mother substrate having a size of 1950×2250mm², according to the fourth embodiment of the present invention.

FIG. 11A illustrates the layout of arranging eight LCD panels (4column×2 row) of the 42-inch model (42WU, picture ratio of 16:9, IPSmode, virtual diagonal length of the 42-inch, panel size of 956.0×549.0mm²) on the mother substrate having a size of 1950×2250 mm². That is,the process key center (1) is provided at the interval of 14 mm from theedge of the mother substrate in the direction of major axis, and thedummy region (2) is provided at the interval of 15 mm from the edge ofthe mother substrate in the direction of minor axis. The eight LCDpanels of the 42-inch model are arranged in a matrix (4 column×2 row) inthe margin of 2.5 mm from the process key center (1), and in the marginof 3 mm from the dummy region (2), wherein the margin between eachcolumn is 6 mm, and the margin between each row is 5 mm. In FIG. 11A,the eight LCD panels of the 42-inch model are arranged in the matrixtype (4 column×2 row), and the major axis of the LCD panel correspondsto the minor axis of the mother substrate. Also, the margin value is notlimited to the above description, which can be controllable within ±30%.

FIG. 11B illustrates the layout of arranging six LCD panels (2 column×3row) of the 47-inch model (47WU, picture ratio of 16:9, IPS mode,virtual diagonal length of 46.96-inch, panel size of 1065×614 mm²) onthe mother substrate having a size of 1950×2250 mm². That is, theprocess key center (1) is provided at the interval of 14 mm from theedge of the mother substrate in the direction of major axis, and theperipheral exposure region (4) is provided at the interval of 27 mm fromthe edge of the mother substrate in the direction of minor axis. The sixLCD panels of the 47-inch model are arranged in a matrix (2 column×3row) in the margin of 14 mm from the process key center (1), and in themargin of 17.5 mm from the peripheral exposure region (4), wherein themargin between each column is 31 mm, and the margin between each row is26 mm. In FIG. 11B, the six LCD panels of the 47-inch model are arrangedin the matrix type (2 column×3 row), and the major axis of the LCD panelcorresponds to the major axis of the mother substrate. Also, the marginvalue is not limited to the above description, which can be controllablewithin ±30%.

FIG. 11C illustrates the layout of arranging sixty six LCD panels (11column×6 row) of the 14.1-inch model on the mother substrate having asize of 1950×2250 mm². That is, the sixty six LCD panels of the14.1-inch model are arranged in a matrix (11 column×6 row) on the mothersubstrate, and the major axis of the LCD panel corresponds to the minoraxis of the mother substrate.

FIG. 11D illustrates the layout of arranging fifty LCD panels (10column×5 row) of 15.4-inch model (15.4W, picture ratio of 16:10, TNmode, virtual diagonal length of 15.38-inch, panel size of 339.8×215mm²) on the mother substrate having a size of 1950×2250 mm², andarranging thirty two LCD panels of the 4-inch model as one row on themother substrate. That is, the fifty LCD panels of 15.4-inch model arearranged in a matrix (10 column×5 row) in the similar margin mentionedabove, and the thirty two LCD panels of the 4-inch model are arranged asone row, wherein the major axis of the LCD panel corresponds to theminor axis of the mother substrate.

FIG. 11E illustrates the layout of arranging fifty four LCD panels (9column×6 row) of the 15-inch model on the mother substrate having a sizeof 1950×2250 mm². That is, the fifty four LCD panels of the 15-inchmodel are arranged in a matrix (9 column×6 row) in the similar marginmentioned above, wherein the major axis of the LCD panel corresponds tothe minor axis of the mother substrate.

FIG. 11F illustrates the layout of arranging forty LCD panels (5column×8 row) of the 17-inch model (picture ratio of 15:9) on the mothersubstrate having a size of 1950×2250 mm². That is, the forty LCD panelsof the 17-inch model are arranged in a matrix (5 column×8 row) in thesimilar margin mentioned above, wherein the major axis of the LCD panelcorresponds to the major axis of the mother substrate.

FIG. 11G illustrates the layout of arranging forty LCD panels (5column×8 row) of the 17-inch model (picture ratio of 15:9) on the mothersubstrate having a size of 1950×2250 mm², and arranging sixteen LCDpanels of 8-inch model as one column on the mother substrate. That is,the forty LCD panels of the 17-inch model are arranged in a matrix (5column×8 row) in the similar margin mentioned above, and the sixteen LCDpanels of 8-inch model are arranged as one column, wherein the majoraxis of the LCD panel corresponds to the major axis of the mothersubstrate.

FIG. 11H illustrates the layout of arranging forty five LCD panels (9column×5 row) of the 17-inch model (picture ratio of 15:10) on themother substrate having a size of 1950×2250 mm². That is, the forty fiveLCD panels of the 17-inch model are arranged in a matrix (9 column×5row) in the similar margin mentioned above, wherein the major axis ofthe LCD panel corresponds to the minor axis of the mother substrate.

FIG. 11I illustrates the layout of arranging thirty LCD panels (5column×6 row) of the 20.1-inch model (picture ratio of 3:4) on themother substrate having a size of 1950×2250 mm². That is, the thirty LCDpanels of the 20.1-inch model are arranged in a matrix (5 column×6 row)in the similar margin mentioned above, wherein the major axis of the LCDpanel corresponds to the major axis of the mother substrate.

FIG. 11J illustrates the layout of arranging thirty LCD panels (5column×6 row) of the 19-inch model (19.0SX, picture ratio of 5:4, TNmode, virtual diagonal length of 18.97-inch, panel size of 387×312 mm²)on the mother substrate having a size of 1950×2250 mm². That is, thethirty LCD panels of the 19-inch model are arranged in a matrix (5column×6 row) in the similar margin mentioned above, wherein the majoraxis of the LCD panel corresponds to the major axis of the mothersubstrate.

FIG. 11K illustrates the layout of arranging thirty LCD panels (5column×6 row) of the 19-inch model (19.0SX, picture ratio of 5:4, TNmode, virtual diagonal length of 18.97-inch, panel size of 387×312 mm²)on the mother substrate having a size of 1950×2250 mm², and arrangingtwelve LCD panels of 8-inch model on the mother substrate. That is, thethirty LCD panels of the 19-inch model are arranged in a matrix (5column×6 row) in the similar margin mentioned above, and the twelve LCDpanels of 8-inch model are arranged as one column on the mothersubstrate, wherein the major axis of the LCD panel corresponds to themajor axis of the mother substrate.

FIG. 11L illustrates the layout of arranging thirty two LCD panels (8column×4 row) of 20-inch model on the mother substrate having a size of1950×2250 mm². That is, the thirty two LCD panels of the 20-inch modelare arranged in a matrix (8 column×4 row) in the similar marginmentioned above, wherein the major axis of the LCD panel corresponds tothe minor axis of the mother substrate.

FIG. 11M illustrates the layout of arranging twenty four LCD panels (4column×6 row) of the 23-inch model (picture ratio of 16:9) on the mothersubstrate having a size of 1950×2250 mm². That is, the twenty four LCDpanels of the 23-inch model are arranged in a matrix (4 column×6 row) inthe similar margin mentioned above, wherein the major axis of the LCDpanel corresponds to the major axis of the mother substrate.

FIG. 11N illustrates the layout of arranging twenty LCD panels (4column×5 row) of the 23-inch model (picture ratio of 16:9) on the mothersubstrate having a size of 1950×2250 mm², and arranging four LCD panelsof the 20.1-inch model (picture ratio of 16:10) as one row on the mothersubstrate. That is, the twenty LCD panels of the 23-inch model arearranged in a matrix (4 column×5 row) in the similar margin mentionedabove, and the four LCD panels of the 20.1-inch model are arranged asone row on the mother substrate, wherein the major axis of the LCD panelcorresponds to the major axis of the mother substrate.

FIG. 11O illustrates the layout of arranging twenty four LCD panels (4column×6 row) of the 23-inch model (picture ratio of 16:9) on the mothersubstrate having a size of 1950×2250 mm², and arranging twelve LCDpanels of the 6.5-inch model (6.5W, picture ratio of 16:9, IPS mode,panel size of 158×93.3 mm²) as one row on the mother substrate. That is,the twenty four LCD panels of the 23-inch model are arranged in a matrix(4 column×6 row) in the similar margin mentioned above, and the twelveLCD panels of the 6.5-inch model are arranged as one row on the mothersubstrate, wherein the major axis of the LCD panel corresponds to themajor axis of the mother substrate.

FIG. 11P illustrates the layout of arranging eighteen LCD panels (6column×3 row) of the 26-inch model (26WU, picture ratio of 16:9, IPSmode, virtual diagonal length of the 26-inch, panel size of 590.9×341.5mm²) on the mother substrate having a size of 1950×2250 mm², andarranging six LCD panels of 10-inch model (10W, picture ratio of 15:9,IPS mode, panel size of 233.8×145.7 mm²) as one column on the mothersubstrate. That is, the eighteen LCD panels of the 26-inch model arearranged in a matrix (6 column×3 row) in the similar margin mentionedabove, and the six LCD panels of 10-inch model are arranged as onecolumn on the mother substrate, wherein the major axis of the LCD panelcorresponds to the minor axis of the mother substrate.

FIG. 11Q illustrates the layout of arranging eighteen LCD panels (6column×3 row) of the 26-inch model (picture ratio of 16:10) on themother substrate having a size of 1950×2250 mm², and arranging eighteenLCD panels of the 6.5-inch model as one row on the mother substrate.That is, the eighteen LCD panels of the 26-inch model are arranged in amatrix (6 column×3 row) in the similar margin mentioned above, and theeighteen LCD panels of the 6.5-inch model are arranged as one row on themother substrate, wherein the major axis of the LCD panel corresponds tothe minor axis of the mother substrate.

FIG. 11R illustrates the layout of arranging twelve LCD panels (3column×4 row) of the 32-inch model (picture ratio of 16:9) on the mothersubstrate having a size of 1950×2250 mm², and arranging three LCD panelsof the 17-inch model (picture ratio of 15:9, IPS mode, virtual diagonallength of 17.10-inch, panel size of 384.68×235.688 mm²) as one row onthe mother substrate. That is, the twelve LCD panels of the 32-inchmodel are arranged in a matrix (3 column×4 row) in the similar marginmentioned above, and the three LCD panels of the 17-inch model arearranged as one row on the mother substrate, wherein the major axis ofthe LCD panel corresponds to the major axis of the mother substrate.

FIG. 11S illustrates the layout of arranging three LCD panels (3column×1 row) of the 55-inch model on the mother substrate having a sizeof 1950×2250 mm², and arranging six LCD panels of the 26-inch model(picture ratio of 16:9) as one row on the mother substrate. That is, thethree LCD panels of the 55-inch model are arranged in a matrix (3column×1 row) in the similar margin mentioned above, and the six LCDpanels of the 26-inch model are arranged as one row on the mothersubstrate, wherein the major axis of the LCD panel corresponds to theminor axis of the mother substrate.

In addition, arranging the eight LCD panels of the 40-inch model has asimilar size mother substrate as arranging the six LCD panels of the47-inch model. To achieve substrate efficiency of 90% or more, the sizeof the mother substrate satisfies 1851˜2057×2121˜2356 mm² when arrangingthe eight LCD panels of the 40-inch model, and the size of the mothersubstrate satisfies 1868˜2075×2171˜2412 mm² when arranging the six LCDpanels of the 47-inch model. Under these conditions, the optimal size ofthe mother substrate satisfying the above two cases is 1870×2200 mm².

The layout of cases for arranging eight LCD panels of the 40-inch modelon the mother substrate (1870×2200 mm²) and arranging six LCD panels ofthe 47-inch model on the mother substrate (1870×2200 mm²) will beexplained as follows. FIGS. 12A to 12M are layouts illustrating therespective models on the mother substrate having a size of 1870×2200mm², according to the fifth embodiment of the present invention.

FIG. 12A illustrates the layout of arranging eight LCD panels (4column×2 row) of 40-inch model (40WU, picture ratio of 16:9, IPS mode,virtual diagonal length of 39.8-inch, panel size of 906×521 mm²) on themother substrate having a size of 1870×2200 mm². That is, the processkey center (1) is provided at the interval of 15 mm from the edge of themother substrate in the direction of major axis, and the dummy region(2) is provided at the interval of 15 mm from the edge of the mothersubstrate in the direction of minor axis. The eight LCD panels of the40-inch model are arranged in a matrix (4 column×2 row) in the margin of9.3 mm from the process key center (1), and in the margin of 17.2 mmfrom the dummy region (2), wherein the margin between each column is17.2 mm, and the margin between each row is 9.4 mm. Accordingly, themargin in the direction of the minor axis of mother substrate is 1.1% ofthe length of LCD panel, and the margin in the direction of the majoraxis of mother substrate is 3.3% of the length of LCD panel. In FIG.12A, the eight LCD panels of the 40-inch model are arranged in thematrix type (4 column×2 row), and the major axis of the LCD panelcorresponds to the minor axis of the mother substrate. Also, the marginvalue is not limited to the above description, which can be controllablewithin ±30%.

FIG. 12B illustrates the layout of arranging six LCD panels (2 column×3row) of the 47-inch model (47WU, picture ratio of 16:9, IPS mode,virtual diagonal length of the 47-inch, panel size of 1065×610.5 mm²) onthe mother substrate having a size of 1870×2200 mm². That is, theprocess key center (1) is provided at the interval of 15 mm from theedge of the mother substrate in the direction of major axis, and thedummy region (2) is provided at the interval of 15 mm from the edge ofthe mother substrate in the direction of minor axis. The six LCD panelsof the 47-inch model are arranged in a matrix (2 column×3 row) in themargin of 2.1 mm from the process key center (1), and in the margin of13.3 mm from the dummy region (2), wherein the margin between eachcolumn is 13.3 mm, and the margin between each row is 2.1 mm.Accordingly, the margin in the direction of the minor axis of mothersubstrate is 0.35% of the length of LCD panel, and the margin in thedirection of the major axis of mother substrate is 3.3% of the length ofLCD panel. In FIG. 12B, the six LCD panels of the 47-inch model arearranged in the matrix type (2 column×3 row), and the major axis of theLCD panel corresponds to the major axis of the mother substrate. Also,the margin value is not limited to the above description, which can becontrollable within ±30%.

FIG. 12C illustrates the layout of arranging six LCD panels (2 column×3row) of 46-inch model (46WU, picture ratio of 16:9, IPS mode, virtualdiagonal length of 46.1-inch, panel size of 1043×600.5 mm²) on themother substrate having a size of 1870×2200 mm². That is, the processkey center (1) is provided at the interval of 15 mm from the edge of themother substrate in the direction of major axis, and the dummy region(2) is provided at the interval of 15 mm from the edge of the mothersubstrate in the direction of minor axis. The six LCD panels of the46-inch model are arranged in a matrix (2 column×3 row) in the margin of9.25 mm from the process key center (1), and in the margin of 28 mm fromthe dummy region (2), wherein the margin between each column is 28 mm,and the margin between each row is 10 mm. Accordingly, the margin in thedirection of the minor axis of mother substrate is 1.67% of the lengthof LCD panel, and the margin in the direction of the major axis ofmother substrate is 2.68% of the length of LCD panel. In FIG. 12C, thesix LCD panels of the 46-inch model are arranged in the matrix type (2column×3 row), and the major axis of the LCD panel corresponds to themajor axis of the mother substrate. Also, the margin value is notlimited to the above description, which can be controllable within ±30%

FIG. 12D illustrates the layout of arranging twelve LCD panels (3column×4 row) of the 32-inch model (32WX, picture ratio of 16:10, IPSmode, virtual diagonal length of 31.5-inch, panel size of 715×413 mm²)on the mother substrate having a size of 1870×2200 mm². That is, thetwelve LCD panels of the 32-inch model are arranged in the matrix type(3 column×4 row), and the major axis of the LCD panel corresponds to themajor axis of the mother substrate.

FIG. 12E illustrates the layout of arranging eighteen LCD panels (6column×3 row) of the 26-inch model (26WX, picture ratio of 16:9, IPSmode, virtual diagonal length of the 26-inch, panel size of 590.9×341.5mm²) on the mother substrate having a size of 1870×2200 mm². That is,the eighteen LCD panels of the 26-inch model are arranged in the matrixtype (6 column×3 row), and the major axis of the LCD panel correspondsto the minor axis of the mother substrate.

FIG. 12F illustrates the layout of arranging twenty four LCD panels (4column×6 row) of the 23-inch model (23WX, picture ratio of 16:9, IPSmode, virtual diagonal length of 22.95-inch, panel size of 523.7×302.7mm²) on the mother substrate having a size of 1870×2200 mm². That is,the twenty four LCD panels of the 23-inch model are arranged in thematrix type (4 column×6 row), and the major axis of the LCD panelcorresponds to the major axis of the mother substrate.

FIG. 12G illustrates the layout of arranging twelve LCD panels (3column×4 row) of the 32-inch model (panel size of 700×455.5 mm²) on themother substrate having a size of 1870×2200 mm². That is, the twelve LCDpanels of the 32-inch model are arranged in the matrix type (3 column×4row), and the major axis of the LCD panel corresponds to the major axisof the mother substrate.

FIG. 12H illustrates the layout of arranging eighteen LCD panels (6column×3 row) of the 26-inch model (panel size of 565×359 mm²) on themother substrate having a size of 1870×2200 mm². That is, the eighteenLCD panels of the 26-inch model are arranged in the matrix type (6column×3 row), and the major axis of the LCD panel corresponds to theminor axis of the mother substrate.

FIG. 12I illustrates the layout of arranging twenty LCD panels (4column×5 row) of the 24-inch model (panel size of 531.9×337.5 mm²) onthe mother substrate having a size of 1870×2200 mm². That is, the twentyLCD panels of the 24-inch model are arranged in the matrix type (4column×5 row), and the major axis of the LCD panel corresponds to themajor axis of the mother substrate.

FIG. 12J illustrates the layout of arranging twenty eight LCD panels (7column×4 row) of 20-inch model (panel size of 447.6×285.1 mm²) on themother substrate having a size of 1870×2200 mm². That is, the twentyeight LCD panels of the 20-inch model are arranged in the matrix type (7column×4 row), and the major axis of the LCD panel corresponds to theminor axis of the mother substrate.

FIG. 12K illustrates the layout of arranging thirty two LCD panels (8column×4 row) of the 19-inch model (19WU, IPS mode, panel size of430.2×274.7 mm²) on the mother substrate having a size of 1870×2200 mm².That is, the thirty two LCD panels of the 19-inch model are arranged inthe matrix type (8 column×4 row), and the major axis of the LCD panelcorresponds to the minor axis of the mother substrate.

FIG. 12L illustrates the layout of arranging twenty four LCD panels (6column×4 row) of the 19-inch model (19SX, picture ratio of 5:4, TN mode,virtual diagonal length of 18.97-inch, panel size of 387×312 mm²) on themother substrate having a size of 1870×2200 mm². That is, the twentyfour LCD panels of the 19-inch model are arranged in the matrix type (6column×4 row), and the major axis of the LCD panel corresponds to theminor axis of the mother substrate.

FIG. 12M illustrates the layout of arranging thirty six LCD panels (6column×6 row) of the 17-inch model (17SX, picture ratio of 5:4, TN mode,virtual diagonal length of 17.04-inch, panel size of 347×278.9 mm²) onthe mother substrate having a size of 1870×2200 mm². That is, the thirtysix LCD panels of the 17-inch model are arranged in the matrix type (6column×6 row), and the major axis of the LCD panel corresponds to themajor axis of the mother substrate.

In addition, arranging eight LCD panels of the 47-inch model has asimilar size mother substrate as arranging six LCD panels of the 55-inchmodel. To achieve substrate efficiency of 90% or more, the size of themother substrate satisfies 2171˜2412×2478˜2753 mm² when arranging theeight LCD panels of the 47-inch model, and the size of the mothersubstrate satisfies 2167˜2408×2508˜2787 mm² when arranging the six LCDpanels of the 55-inch model. Under these conditions, the optimal size ofthe mother substrate satisfying the above two cases is 2200×2500 mm².

The layout of cases for arranging eight LCD panels of the 47-inch modelon the mother substrate (2200×2500 mm²) and arranging six LCD panels ofthe 55-inch model on the mother substrate (2200×2500 mm²) will beexplained as follows. FIGS. 13A to 13G are layouts illustrating therespective models on the mother substrate having a size of 2200×2500mm², according to the sixth embodiment of the present invention.

FIG. 13A illustrates the layout of arranging eight LCD panels (4column×2 row) of the 47-inch model (47WU, picture ratio of 16:9, IPSmode, virtual diagonal length of 47.0-inch, panel size of 1065×610.5mm²) on the mother substrate having a size of 2200×2500 mm². That is,the process key center (1) is provided at the interval of 15 mm from theedge of the mother substrate in the direction of major axis, and thedummy region (2) is provided at the interval of 15 mm from the edge ofthe mother substrate in the direction of minor axis. The eight LCDpanels of the 47-inch model are arranged in a matrix (4 column×2 row) inthe margin of 13.3 mm from the process key center (1), and in the marginof 6 mm from the dummy region (2), wherein the margin between eachcolumn is 6 mm, and the margin between each row is 13.3 mm. Accordingly,the margin in the direction of the minor axis of mother substrate is1.6% of the length of LCD panel, and the margin in the direction of themajor axis of mother substrate is 1% of the length of LCD panel. In FIG.13A, the eight LCD panels of the 47-inch model are arranged in thematrix type (4 column×2 row), and the major axis of the LCD panelcorresponds to the minor axis of the mother substrate. Also, the marginvalue is not limited to the above description, which can be controllablewithin ±30%.

FIG. 13B illustrates the layout of arranging six LCD panels (2 column×3row) of the 55-inch model (55WU, picture ratio of 16:9, IPS mode,virtual diagonal length of 54.6-inch, panel size of 1233×710 mm²) on themother substrate having a size of 2200×2500 mm². That is, the processkey center (1) is provided at the interval of 15 mm from the edge of themother substrate in the direction of major axis, and the dummy region(2) is provided at the interval of 10 mm from the edge of the mothersubstrate in the direction of minor axis. The six LCD panels of the55-inch model are arranged in a matrix (2 column×3 row) in the margin of10 mm from the process key center (1), and in the margin of 4.7 mm fromthe dummy region (2), wherein the margin between each column is 4.6 mm,and the margin between each row is 10 mm. Accordingly, the margin in thedirection of the minor axis of mother substrate is 1.5% of the length ofLCD panel, and the margin in the direction of the major axis of mothersubstrate is 0.4% of the length of LCD panel. In FIG. 13B, the six LCDpanels of the 55-inch model are arranged in the matrix type (2 column×3row), and the major axis of the LCD panel corresponds to the major axisof the mother substrate. Also, the margin value is not limited to theabove description, which can be controllable within ±30%.

FIG. 13C illustrates the layout of arranging six LCD panels (2 column×3row) of the 52-inch model (52WU, picture ratio of 16:9, IPS mode,virtual diagonal length of the 52-inch, panel size of 1174.5×670.5 mm²)on the mother substrate having a size of 2200×2500 mm². That is, theprocess key center (1) is provided at the interval of 15 mm from theedge of the mother substrate in the direction of major axis, and thedummy region (2) is provided at the interval of 15 mm from the edge ofthe mother substrate in the direction of minor axis. The six LCD panelsof the 52-inch model are arranged in a matrix (2 column×3 row) in themargin of 39.25 mm from the process key center (1), and in the margin of40 mm from the dummy region (2), wherein the margin between each columnis 41 mm, and the margin between each row is 40 mm. Accordingly, themargin in the direction of the minor axis of mother substrate is 6% ofthe length of LCD panel, and the margin in the direction of the majoraxis of mother substrate is 3.5% of the length of LCD panel. In FIG.13B, the six LCD panels of the 52-inch model are arranged in the matrixtype (2 column×3 row), and the major axis of the LCD panel correspondsto the major axis of the mother substrate. Also, the margin value is notlimited to the above description, which can be controllable within ±30%.

FIG. 13D illustrates the layout of arranging eighteen LCD panels (6column×3 row) of the 32-inch model (32WX picture ratio of 16:10, IPSmode, virtual diagonal length of 31.5-inch, panel size of 715×413 mm²)on the mother substrate having a size of 2200×2500 mm². That is, theeighteen LCD panels of the 32-inch model are arranged in the matrix type(6 column×3 row), and the major axis of the LCD panel corresponds to theminor axis of the mother substrate.

FIG. 13E illustrates the layout of arranging twenty four LCD panels (4column×6 row) of the 26-inch model (26WX picture ratio of 16:9, IPSmode, virtual diagonal length of the 26-inch, panel size of 590.9×341.5mm²) on the mother substrate having a size of 2200×2500 mm². That is,the twenty four LCD panels of the 26-inch model are arranged in thematrix type (4 column×6 row), and the major axis of the LCD panelcorresponds to the major axis of the mother substrate.

FIG. 13F illustrates the layout of arranging twenty eight LCD panels (7column×4 row) of the 24-inch model (panel size of 531.9×337.5 mm²) onthe mother substrate having a size of 2200×2500 mm². That is, the twentyeight LCD panels of the 24-inch model are arranged in the matrix type (7column×4 row), and the major axis of the LCD panel corresponds to theminor axis of the mother substrate.

FIG. 13G illustrates the layout of arranging thirty five LCD panels (5column×7 row) of the 22-inch model (panel size of 483.26×305.6 mm²) onthe mother substrate having a size of 2200×2500 mm². That is, the thirtyfive LCD panels of the 22-inch model are arranged in the matrix type (5column×7 row), and the major axis of the LCD panel corresponds to themajor axis of the mother substrate.

In addition, arranging eight LCD panels of the 47-inch model has asimilar size mother substrate as arranging six LCD panels of the 57-inchmodel. To achieve substrate efficiency of 90% or more, the size of themother substrate satisfies 2171˜2412×2478˜2753 mm² when arranging theeight LCD panels of the 47-inch model, and the size of the mothersubstrate satisfies 2167˜2408×2508˜2787 mm² when arranging the six LCDpanels of the 57-inch model. Under these conditions, the optimal size ofthe mother substrate satisfying the above two cases is 2230×2600 mm².

The layout of cases for arranging eight LCD panels of the 47-inch modelon the mother substrate (2230×2600 mm²) and arranging six LCD panels ofthe 57-inch model on the mother substrate (2230×2600 mm²) will beexplained as follows. FIGS. 14A to 14J are layouts illustrating therespective models on the mother substrate having a size of 2230×2600mm², according to the seventh embodiment of the present invention.

FIG. 14A illustrates the layout of arranging eight LCD panels (4column×2 row) of the 47-inch model (47WU, picture ratio of 16:9, IPSmode, virtual diagonal length of 47.0-inch, panel size of 1065×610.5mm²) on the mother substrate having a size of 2230×2600 mm². That is,the process key center (1) is provided at the interval of 15 mm from theedge of the mother substrate in the direction of major axis, and thedummy region (2) is provided at the interval of 15 mm from the edge ofthe mother substrate in the direction of minor axis. The eight LCDpanels of the 47-inch model are arranged in a matrix (4 column×2 row) inthe margin of 23.3 mm from the process key center (1), and in the marginof 26 mm from the dummy region (2), wherein the margin between eachcolumn is 26 mm, and the margin between each row is 23.3 mm.Accordingly, the margin in the direction of the minor axis of mothersubstrate is 2.2% of the length of LCD panel, and the margin in thedirection of the major axis of mother substrate is 4.3% of the length ofLCD panel. In FIG. 14A, the eight LCD panels of the 47-inch model arearranged in the matrix type (4 column×2 row), and the major axis of theLCD panel corresponds to the minor axis of the mother substrate. Also,the margin value is not limited to the above description, which can becontrollable within ±30%.

FIG. 14B illustrates the layout of arranging six LCD panels (2 column×3row) of the 57-inch model (57WU, picture ratio of 16:9, IPS mode,virtual diagonal length of 57.0-inch, panel size of 1276.2×727.2 mm²) onthe mother substrate having a size of 2230×2600 mm². That is, theprocess key center (1) is provided at the interval of 15 mm from theedge of the mother substrate in the direction of major axis, and thedummy region (2) is provided at the interval of 15 mm from the edge ofthe mother substrate in the direction of minor axis. The six LCD panelsof the 57-inch model are arranged in a matrix (2 column×3 row) in themargin of 4.6 mm from the process key center (1), and in the margin of5.9 mm from the dummy region (2), wherein the margin between each columnis 5.8 mm, and the margin between each row is 4.6 mm. Accordingly, themargin in the direction of the minor axis of mother substrate is 0.6% ofthe length of LCD panel, and the margin in the direction of the majoraxis of mother substrate is 0.5% of the length of LCD panel. In FIG.14B, the six LCD panels of the 57-inch model are arranged in the matrixtype (2 column×3 row), and the major axis of the LCD panel correspondsto the major axis of the mother substrate. Also, the margin value is notlimited to the above description, which can be controllable within ±30%.

FIG. 14C illustrates the layout of arranging six LCD panels (2 column×3row) of the 52-inch model (52WU, picture ratio of 16:9, IPS mode,virtual diagonal length of the 52-inch, panel size of 1174.5×670.5 mm²)on the mother substrate having a size of 2230×2600 mm². That is, theprocess key center (1) is provided at the interval of 15 mm from theedge of the mother substrate in the direction of major axis, and thedummy region (2) is provided at the interval of 15 mm from the edge ofthe mother substrate in the direction of minor axis. The six LCD panelsof the 52-inch model are arranged in a matrix (2 column×3 row) in themargin of 47.25 mm from the process key center (1), and in the margin of73.5 mm from the dummy region (2), wherein the margin between eachcolumn is 74 mm, and the margin between each row is 47 mm. Accordingly,the margin in the direction of the minor axis of mother substrate is 7%of the length of LCD panel, and the margin in the direction of the majoraxis of mother substrate is 6.3% of the length of LCD panel. In FIG.14C, the six LCD panels of the 52-inch model are arranged in the matrixtype (2 column×3 row), and the major axis of the LCD panel correspondsto the major axis of the mother substrate. Also, the margin value is notlimited to the above description, which can be controllable within ±30%.

FIG. 14D illustrates the layout of arranging six LCD panels (2 column×3row) of the 55-inch model (55WU, picture ratio of 16:9, IPS mode,virtual diagonal length of 54.6-inch, panel size of 1233×710 mm²) on themother substrate having a size of 2230×2600 mm². That is, the processkey center (1) is provided at the interval of 15 mm from the edge of themother substrate in the direction of major axis, and the dummy region(2) is provided at the interval of 15 mm from the edge of the mothersubstrate in the direction of minor axis. The six LCD panels of the55-inch model are arranged in a matrix (2 column×3 row) in the margin of26 mm from the process key center (1), and in the margin of 23 mm fromthe dummy region (2), wherein the margin between each column is 24 mm,and the margin between each row is 26 mm. Accordingly, the margin in thedirection of the minor axis of mother substrate is 3.7% of the length ofLCD panel, and the margin in the direction of the major axis of mothersubstrate is 1.9% of the length of LCD panel. In FIG. 14D, the six LCDpanels of the 55-inch model are arranged in the matrix type (2 column×3row), and the major axis of the LCD panel corresponds to the major axisof the mother substrate. Also, the margin value is not limited to theabove description, which can be controllable within ±30%.

FIG. 14E illustrates the layout of arranging twelve LCD panels (3column×4 row) of the 37-inch model (37WU, picture ratio of 16:9, IPSmode, virtual diagonal length of the 37-inch, panel size of 846.0×485.2mm²) on the mother substrate having a size of 2230×2600 mm². That is,the twelve LCD panels of the 37-inch model are arranged in a matrix (3column×4 row) in the similar margin mentioned above, and the major axisof the LCD panel corresponds to the major axis of the mother substrate.

FIG. 14F illustrates the layout of arranging eighteen LCD panels (6column×3 row) of the 32-inch model (32WX, picture ratio of 16:9, IPSmode, virtual diagonal length of 31.5-inch, panel size of 715.0×413.05mm²) on the mother substrate having a size of 2230×2600 mm². That is,the eighteen LCD panels of the 32-inch model are arranged in a matrix (6column×3 row) in the similar margin mentioned above, and the major axisof the LCD panel corresponds to the minor axis of the mother substrate.

FIG. 14G illustrates the layout of arranging twenty four LCD panels (4column×6 row) of the 26-inch model (26WX, picture ratio of 16:9, IPSmode, virtual diagonal length of the 26-inch, panel size of 590.9×341.5mm²) on the mother substrate having a size of 2230×2600 mm². That is,the twenty four LCD panels of the 26-inch model are arranged in a matrix(4 column×6 row) in the similar margin mentioned above, and the majoraxis of the LCD panel corresponds to the major axis of the mothersubstrate.

FIG. 14H illustrates the layout of arranging twenty eight LCD panels (7column×4 row) of the 24-inch model (panel size of 531.9×337.5 mm²) onthe mother substrate having a size of 2230×2600 mm², and arranging eightLCD panels of 10.2-inch model (10W, picture ratio of 15:9, IPS mode,panel size of 233.8×145.7 mm²) as one column on the mother substrate.That is, the twenty eight LCD panels of the 24-inch model are arrangedin a matrix (7 column×4 row), and the eight LCD panels of 10-inch modelare arranged as one column in the similar margin mentioned above,wherein the major axis of the LCD panel corresponds to the minor axis ofthe mother substrate.

FIG. 14I illustrates the layout of arranging thirty two LCD panels (8column×4 row) of the 23-inch model (panel size of 504.86×319.1 mm²) onthe mother substrate having a size of 2230×2600 mm². That is, the thirtytwo LCD panels of the 23-inch model are arranged in a matrix (8 column×4row) in the similar margin mentioned above, wherein the major axis ofthe LCD panel corresponds to the minor axis of the mother substrate.

FIG. 14J illustrates the layout of arranging thirty five LCD panels (5column×7 row) of the 22-inch model (panel size of 483.26×305.6 mm²) onthe mother substrate having a size of 2230×2600 mm². That is, the thirtyfive LCD panels of the 22-inch model are arranged in a matrix (5column×7 row) in the similar margin mentioned above, wherein the majoraxis of the LCD panel corresponds to the major axis of the mothersubstrate.

As mentioned above, the layout of the LCD panel and the substrate sizeaccording to the present invention has the following advantages.

First, it is possible to provide the size of the mother substrate whichcan realize the substrate efficiency of 90% or more in the respectivemodels, to thereby decrease the manufacturing cost.

Also, it is possible to provide the data for arranging the LCD panels ofthe same model or the different models at maximum on the mothersubstrate having the predetermined size, thereby improving theproductivity with the maximum substrate efficiency.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the spirit or scope of the inventions. Thus, itis intended that the present invention covers the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

1. A method of manufacturing liquid crystal display (LCD) devices,comprising: providing a plurality of mother substrates having a majoraxis and a minor axis, wherein the length of the major axis of eachmother substrate is the same and the length of the minor axis of eachmother substrate is the same, and wherein the major axis and the minoraxis of the plurality of mother substrates have lengths according to thefollowing: selecting first characteristics of a first plurality of LCDpanels and selecting second characteristics of a second plurality of LCDpanels, said characteristics including: a diagonal length, an aspectratio of a length of the LCD panel in a first direction to a length ofthe LCD panel in a second direction different from said first direction,and an operating mode; choosing a first number of the first plurality ofLCD panels to provide on a first of the mother substrates and choosing asecond number of the second plurality of LCD panels to provide on asecond of the mother substrates; choosing an alignment of the major axisof the first LCD panels to be parallel to the major axis of the firstmother substrate and choosing an alignment of the minor axis of thesecond LCD panels to be parallel to the major axis of the second mothersubstrate; choosing a size of a dummy region at an edge of the firstmother substrate and choosing a size of a dummy region at an edge of thesecond mother substrate; choosing a first margin of the first mothersubstrate and a first margin of the second mother substrate, said firstmargins including: a distance between adjacent LCD panels on the mothersubstrate in the first direction, and a distance between the dummyregion and the LCD panels in the first direction; and choosing a secondmargin of the first mother substrate and a second margin of the secondmother substrate, said second margins including: a distance betweenadjacent LCD panels on the mother substrate in the second direction, anda distance between the dummy region and the LCD panels in the seconddirection, wherein the length of the major axis of the mother substratesand the length of the minor axis of the mother substrates are based onsaid first and second LCD panel characteristics, the first number andthe second number of LCD panels, the alignment of the first and secondLCD panels relative to the first and second mother substrates, the firstand second margins, and said sizes of the dummy regions, such that asubstrate efficiency of 90% or more is achieved in the major and minoraxis directions for first mother substrate and a substrate efficiency of90% or more is achieved in the major and minor axis directions for thesecond mother substrate, wherein a substrate efficiency calculation of100% is based on assuming a total dummy region width of 30 mm or lessand a margin of 0.3 to 4%, and wherein the size of the mother substrateis 1500 mm by 1850 mm; forming the first number of the first pluralityof LCD panels on the first mother substrate; and forming the secondnumber of the second plurality of LCD panels on the second mothersubstrate.
 2. The method of claim 1, further comprising: providing asealant and a black matrix layer around each of said first and secondLCD panels, wherein the sealant overlaps the black matrix layer.
 3. Themethod of claim 1, wherein the first margins are between approximately0.3% and about 5% of the length of the LCD panels in the firstdirection, and the second margins are between approximately 0.3% andabout 5% of the length of the LCD panels in the second direction.
 4. Themethod of claim 1, wherein: the diagonal length of the second LCD panelsis 32 inches; the second number of second LCD panels is eight.
 5. Themethod of claim 4, wherein the aspect ratio of the 32-inch LCD panels is16:9; and wherein the length of the 32-inch LCD panels in the firstdirection is 413.05 mm and the length of the 32-inch LCD panels in thesecond direction is 715.0 mm.
 6. The method of claim 1, wherein thesubstrate efficiency calculation of 100% is based on assuming a totaldummy region width of 30 mm and a margin of 1%.
 7. A method ofmanufacturing liquid crystal display (LCD) devices, comprising:providing a plurality of mother substrates having a major axis and aminor axis, wherein the length of the major axis of each mothersubstrate is 1850 mm and the length of the minor axis of each mothersubstrate is 1500 mm; forming a first number of a first plurality of LCDpanels on a first of the plurality of mother substrates, wherein thefirst LCD panels have a first diagonal length and have a major axisaligned to be parallel to the major axis of the first mother substrate,wherein a substrate efficiency of 90% or more is achieved in the majorand minor axis directions for the first mother substrate, wherein asubstrate efficiency calculation of 100% is based on assuming a totaldummy region width of 30 mm or less and a margin of 0.3 to 4%; andforming a second number of a second plurality of LCD panels on a secondof the plurality of mother substrates, wherein the second LCD panelshave a second diagonal length and have a minor axis aligned to beparallel to the major axis of the second mother substrate, wherein asubstrate efficiency of 90% or more is achieved in the major and minoraxis directions for the second mother substrate, wherein a substrateefficiency calculation of 100% is based on assuming a total dummy regionwidth of 30 mm or less and a margin of 0.3 to 4%.
 8. The method of claim7, wherein the substrate efficiency calculation of 100% is based onassuming a total dummy region width of 30 mm and a margin of 1%.